Progressife switch



Jan. 7, 1964 A. CARLING ETAL PROGRESSIVE swITcH 3 Sheets-Sheet 1 Filed Feb. 15, 1961 mmm.

Jan. 7, 1964 A. cARLlNG ETAL.

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Jan. 7, A1964 A. cARLlNG ETAL PROGRESSIVE SWITCH 5 Sheet-Sheet .'5

Filed Feb. 15. 1961 Ilnited States Patent O 3,117,197 PRUGEIISSIVE SWITCH Arthur Cariing and Wesiey I. Sorenson, West Hartford,

Corin., assignors to Carling Electric, Inc., West Hartford, Conn., a corporation of Connecticut Filed Feb. 15, 1961, Ser. No. 89,428 Claims. (Cl. 200-67) This invention relates generally to switches, and particularly to an improved single pole progressive switch capable of controlling at least two electrical circuits.

The present invention constitutes a single pole, progressive switch, arranged to control at least two electrical circuits in a sequence as follows: both circuits otf; one circuit on; and two circuits on; said electrical conditions being selectable in forward, reverse, or mixed sequence.

These functions of the invention are performed, in one embodiment, by a circuit contact lever acting pivotably on a yoke positioned between two contact elements. One of these contact elements constitutes a spring biased contact finger with which one arm of the contact lever makes electrical connection during two of its circuit controlling positions while the other contact arm makes electrical connection with the other element in oniy one of said two positions. In a third position of said contact lever both contact arms of said lever are spaced apart from the respective contact elements in which condition both of the circuits controlled by the switch are in the open condition.

In one embodiment of the invention where the circuit elements of the switch are to be arrayed symmetrically in the switch case for simplicity and economy of manufacture, and in which the symmetrical contact lever would normally impinge upon one of the contact elements when the circuit controlled thereby is desired to remain in the open condition, a novel arrangement is provided for interposing an insulating element or structure between the contact lever and said particular contact element to prevent electrical connection being made therebetween in one position of said lever. There is further provided an auxiliary spring biased contact nger connected to said contact element and arrayed in such a manner in the switch case whereby the contact lever is electrically connected to said spring biased contact linger in two of its other operating positions as a result of which said particular circuit is in the closed condition.

The second contact element is impinged by said circuit lever during the third of the three operating positions of said lever in order to close the circuit controlled by said second contact element while the lever is making electrical connection with said contact iinger and maintaining the other circuit closed.

The circuit lever is moved from one circuit position to a succeeding circuit position by operation of a toggle, slide, push, tipper or other type of actuator mechanism containing a spring actuated pin which yieldably maintans the lever in any selected one of the various circuit positions until the pin is moved into other selected circuit positions.

The switch of the present invention comprises an arrangement of simple stamped and molded parts which are inexpensive to fabricate and which are easily assembled. Since the working parts are subjected to comparatively little stress, the switch is capable of performing for long periods of time without failure.

Still other objects and advantages of the invention will be apparent from the specification.

The features of novelty which are believed to be characteristic of the invention are set forth herein and will best be understood, both as to their fundamental prinice ciples and as to their particular embodiments by reference to the specication and accompanying drawings, in which:

FIGURE 1 is a perspective view of a typical switch assembly embodying the present invention;

FIG. 2 is a greatly enlarged vertical section view, taken on line 2 2 of FIG. 1; some parts being shown in elevation, and showing the circuit lever in a position where both electrical circuits are open;

FIG. 3 is similar to FIG. 2, except that the toggle element has moved the control pin into a position where one circuit is closed;

FIG. 4 is similar to FIGS. 2 and 3, except that the toggle element has moved the control pin into a position where two circuits are closed;

FIG. 5 is a still further enlarged view, taken on line 5-5 of FIG. 2, some parts being omitted;

FIG. 6 is a view taken on line 6-6 of FIG. 4;

FIG. 7 is a View taken on line 7-7 of FIG. 2, some parts being omitted;

FIGS. 8, 9 and 10 constitute a series of fragmentary views extracted from FIG. 7, showing different relative positions of the portions of the circuit lever and the respective contact element as they are shown in side view in FIGS. 2, 3 and 4, respectively;

FIG. 1l is a greatly enlarged exploded view of the yoke and circuit lever elements as well as one of the contact elements forming part of the mechanism of the present invention;

FIG. 12 is a fragmentary view showing a contact element somewhat modiiied in form from that shown in the previous figures;

FIG. 13 is a View similar to FIG. 5, showing a different form of spring biased contact element;

FIG. 14 is a section View taken on line 11i-14 of FIG. 13, some parts being shown in elevation;

FIGS. 15, 16 and 17 are slightly reduced section views taken on line 15-15 of FIG. 13, comparable to FIGS. 2, 3 and 4, showing the different positions in which the circuit lever of FIGS. 13 and 14 is operable to produce the switching action described hereinabove;

FIG. 18 is a greatly enlarged perspective view of one of the contact elements shown in FIGS. 13 through 17;

FIG. 19 is a fragmentary side view of an alternative embodiment of the contact element shown in FIGS. 13 through 18, some parts being shown in dotted outline;

FIG. 20 is a fragmentary View of the contact lever and contact element showing another means for providing electrical insulation therebetween; and

FIG. 21 is a fragmentary view of the contact lever and a contact element showing a still further means for preventing electrical connection being made therebetween.

Referring now to the drawings in detail, the switch of the present invention comprises a box-like molded case, generally designated 21, made of a suitable electrically insulating material such as synthetic resin, Bakelite, or the like, and having a pair of opposing end walls 22, and a pair of side walls 23. The bottom of case 21 is enclosed by a floor 24.

The open top of case 21 is covered by a top plate 25 made of a suitable material such as sheet metal, or the like, and whose ends are substantially co-extensive with the outer surfaces of respective end walls 22. The sides of top plate 25 are recessed to coincide with recesses 26 in the outer surfaces of side walls 23 of case 21. See FIGS. 5 and 6. Top plate 25 has a central aperture 27 through which various switch actuating elements project, as will be described hereinbelow.

Positioned over top plate 25 is a bracket 31 of sheet metal, which has a central, circular aperture, coaxial with aperture 27 in plate 25. Bracket 31 has a pair of opposed downwardly extending leaves 32 which iit within respective recesses 26 of side walls 23. The lower end of each leaf 32 is provided with a pair oi spaced apart lugs 33 which tensionally grasp respective recesses, not shown, in the bottom surface of floor 24m cause bracket El to secure top plate firmly on the top of case 2l.

A tubular threaded bushing 36 is secured at its lower end by suitable means, such as a force fit or the like, between top plate 25 and bracket 3l at the inner peripheral areas surrounding their respective central apertures for firm connection to case 2l.

The interior wall of bushing 36 has an inwardly curving annular shoulder 37 intermediate its ends, said shoulder being adapted to cooperate with a toggle element 3S, a portion of whose surface is curved to mate movably with said shoulder, whereby said toggle may move pivotally relative to said bushing. Toggle 3S has an upwardly extending handle 39 for manual operation, and a lower tubular extension 41. Handle 39 has a bore 42, toggle has a bore 43 and tube di has a bore Lili, all of said bores being axially aligned and longitudinally accommodating an elongated control pin which is normally vurged outwardly from bore i4 by captive spring 4e. Control pin 45 is made of a suitable electrically insulating material, such as Bakelite, nylon, or the like, and has an outer end of slightly reduced diameter in the form of a smoothly rounded nib i7 extending downwardly to actuate the movable circuit contact lever of the switch, as will be described hereinbelow. While nib 47 is being urged downwardly against the circuit lever, spring i6 acting upon ythe inner end of bore 42 urges toggle 33 upwardly and snugly against shoulder 37 without preventing pivotal motion of said toggle relative to bushing 36.

Positioned in iioor 24 of case 2l is a pair of spaced apart, electrically conducting studs :'51 and 52 which extend through said iioor and are incorporated securely therein by means of molding or the like. Stud 51 has a rivet head 53 .and stud 52 has an electrically conducting contact head 54, respectively, which extend into the interior of case 2l. The lower ends of said studs on the outer surface of floor 2Liyhave rivet heads 55 and S6, respectively, which firmly secure electrically conductive ybrackets 57 and S8, to the bottom of said case. Brackets 57 and 58 have downwardly extending electrically conducting lugs 6l and 62, respectively, which serve as terminals vto which separate electrical circuits are conneCtibIe.

Positioned intermediate studs 5l and 52 is an electri- .cally conducting stud 63 which also extends through oor 24 and is Vincorporated securely therein by means of molding or the like. The lower end of stud 63 extends downwardly to the exterior of case 2l and has a rivet head 64 which firmly secures an electrically conductive bracket 65 to the bottom of said case. Bracket 65 has a down- -wardly extending lug 66 which serves as a terminal t0 which an electrical circuit is connectible that is common to the other two circuits that are controllable by the switch herein. The upper end of stud 63 extends into the interior of case 2l and through a central aperture in the lbase of an electrically conducting support or yoke 67.

Positioned between the base of yoke 67 and the top surface of floor 24 is one end portion of a flexible insulating leaf 68 made of a suitable material such as paperboard, frberboard, rubber, plastic or the like. Stud 63 has a rivet head 69 which secures yoke 67 and leaf 68 to licor 24 of case 2l. The free `flexible pad portion 71 of leaf 68 extends obliquely upwardly and terminates in a position generally above rivet head 53.

Yoke 67 has a pair of upwardly extending arms 72 each of which terminates in a pair of spaced apart, short ngers 73 and 74. Between each pair of lingers 73 and "i4, on each of arms 72 are shoulders 76 and 77, respectively, which serve as fulcrums for an electrically conductive circuit contact lever, generally designated 78, freely supported pivotally thereon. V-shaped circuit lever 7S has a pair of lever arms Si and 82 extending in opposite directions and arrayed at an angle relative to each other. Lever arms 8l and 82 are joined by an integral, central, slightly arcuate portion S3 which is slightly extended laterally and is positioned between upwardly extending arms 72 of yoke e7. Connected to the outer end portion of lever arm 8l is a contact button S4 which, upon pivoting action of lever 78, makes or breaks an electrical circuit .in respect of contact head 54. See FIGS. 2-4 and ll.

Secured by rivet head 53 of stud 5l to case 2l is the base of a circuit contact element 86 made of a suitable electrically conductive resilient spring metal. Contact element 86 has a pair of upwardly extending arms 87 and 'S8 which have inwardly extending shoulders 9i and 92, respectively, which terminate in upwardly extending iiners 93 and 94, respectively. Said arms, shoulders and lingers are normally arrayed as shown in FIG. 8, for example.

As can be seen from FIGS. 2, 3 and 4, contact circuit lever 7S is freely pivotable on shoulders 76 and 77 of yoke 67, with the apex between its arms 8l and 82 resting between shoulders 76 and 77 o f yoke 67. In a rst position as exemplified in FIG. 2, when nib 47 is moved to the right by the leftward action of toggle handle 39, said nib urging downwardly upon lever arm S2 intermediate its ends, one end of lever arm S2 rests upon shoulder 77 of yoke 67 -and its other end is pressed downwardly on insulating pad 71 which effectively prevents kan electrical circuit being established between contact lever 78 and rivet head S3. See also FIGS. 7 and 8. In this position of circuit lever 78, contact button 84 is spaced apart in open circuit relationship from the contact head 54.

When toggle handle 39 is manipulated to the vertical position, as shown in FIG. 3, and nib 47 has yieldably moved along arm 82 to a position where it bears centrally down upon portion 83 of circuit lever 78, lever arm 81 and lever arm 82 are resting upon respective shoulders 76 and 77 of yoke 67. -In this position it can vbe seen that lever arm 82 has now been raised to a position where it has come in electrical contact with lingers 93 and 94 of circuitelernent 86. See also FIG. 9. In this position of ,lever 78, the electrical circuit is closed between lugs 61 and 66. Also, as was the condition in FIG. 2, contact button -84 on lever armV 81 is still spaced apart from contact head S4 so that there is no electrical circuit established therebetween. Thus, in the position as shown in FIG. 3, one circuit is in the closed position as established electrically through lug 61, stud 51, fingers 93, 94 of circuit element 86, lever arm 82, yoke 67, stud 63 and lug 66.

When toggle arm 39 is manipulated to the right as shown in IFIG. 4, nib 47 has caused circuit lever 7S to move pivotally on shoulder 76 of yoke 67 and urges yieldably downwardly upon lever arm 81 intermediate its ends, whereby contact button 84 establishes electrical connection with contact head 54 on stud 52. At the same time, as lever arm 82 has risen, it has still maintained electrical contact with circuit element S6 by virtue of the spring biasing action of lingers 93 and 94, bearing against the lateral edges of said lever arm. See also FIG. 10. In the position as shown in FIG. 4, the previously closed circuit condition between terminal lugs 61 and 66 is maintained, while a second electrical circuit is established from terminal lug 62 through stud 52, -lever arm S1, yoke 67, stud 6-3, to terminal lug 66.

In some embodiments of the switches of the present invention,` the double fingered contact element 86 may be replaced by a single fingered contact element 96, as shown in FIG. 12, for example. In this embodiment -elementf96has anupwardly extending yarm 97, an inwardly extending shoulder 98, and a generally upwardly extending nger 99, said element 96 being made of a sulficiently resilient sheet meta-l material that normally causes linger 99 to be urged inwardly and against lever arm S2 as it rises to the various electrical contacting positions shown in dotted outline in FIG. 12 comparable to those lshown in FIGS. 9 and l0.

A further embodiment of the switches of the present invention is shown in FIGS. 13 through 18, wherein similar reference numerals identify parts similar to those in the previous figures. In the embodiment of FIGS. 13 through 18, contact element 86 of the previous embodiments has been replaced by a contact element 101, made of a suitable electrically conductive resilient sheet metal such as Phosphor bronze, or the like. Contact element 101 is electrically connected to stud 51 by a rivet head 53. As is the arrangement in the structure of FIGS. 2 through 10, insulating pad 71 is arranged to electrically separate lever arm S2 from rivet head S3 thereby preventing any electrical circuitry being established therebetween.

Contact element 101 has an upwardly extending arm 102 at the upper end of which is a reverse loop 103 which terminates in an inwardly and downwardly extending contact finger 104, said finger having sufficient resilience to return to its original position, as shown in FIGS. 15 and 18 for example, after it has been distorted out of its original position, as shown in FIGS. 16 and 17, for example. Here also, as in the previously described embodiment, FIG. 15 shows both circuits in the off position, while FIG. 16 shows lever 82 having made contact with finger 104 to establish an electrical circuit between terminal lugs 61 and 66. Upon further pivoting action of toggle arm 39, where nib 47 has caused contact button 84 to impinge upon contact head 54 to establish an electrical circuit between terminal lugs 62 and 66, it will be seen that lever arm 82 still maintains contact with finger 104 of contact arm 101, thereby maintaining the previously established closed circuit between terminal lugs 61 and 66.

Contact element 101 may further be modified as shown in FIG. 19, where an electrically conducting contact element 106 is shown with an upwardly extending arm 107 terminating in an inwardly biased spring finger 108 with which electrical connection is made and maintained by lever arm 32 in the various positions thereof as described hereinabove in connection with the other embodiments of the invention. In some embodiments, iiexible insulating pad 71 may be dispensed with and rivet head 53 covered with an insulating cap 111 as shown in FIG. 20, in order to prevent electrical connection being made between contact arm 82 and rivet 51 in the switch positions shown in FIGS. 2 and 15. Other suitable means may be provided for preventing electrical connection between contact arm 82 and its associated contact element when the open circuit condition is desired, such as recessing head 53 of rivet 51 below the inside iioor of case 21 so that in the positions of FIGS. 2 and 15, contact arm 82 rests upon the insulating material of which said case is constituted, as shown in FIG. 21.

In the embodiments described hereinabove, the insulating means for preventing electrical connection between contact arm 82 and rivet head 53 are of particular significance when it is preferred, for simple and low cost manufacture, to fabricate a switch case 21 having a symmetrical arrangement of terminal lugs 61 and 62 to which various electrical circuits may be connected for control by the switch. In other forms of the invention, however, rivet 51, lug 61, and contact elements 86 and 101 may be positioned in other parts of case 21 whereby contact arm 82 is caused to impinge upon a portion of the insulating case itself when nib 47 urges it downwardly as in FIGS. 2 and 15, while in the positions of FIGS. 3, 4, 16 and 17, said contact arm is in electrical connection with contact element fingers 93, 94, 99 or 104.

It is claimed:

1. A progressive switch comprising a case made of insulating material, first and second spaced apart circuit contact elements in said case, first and second spaced apart portions on said first contact element, an electrically conductive support yoke positioned in said case intermediate said rst and second contact elements, a pair of spaced apart pivot shoulders on said yoke, an electrically conductive lever mounted pivotally on said shoulders and positionable at will in any one of three positions relative thereto, first and second contact arms on said lever each extending in opposite directions from and arrayed at an angle relative to each other, an insulating pad mounted in said case and interposed between said first contact arm and said first portion of said first contact element, an actuator element mounted in said case, the first and second portions of said first contact element being disposed within said case, means including said actuator element operative to resiliently urge said lever into any of said three positions to bring about any selected one of the following electrical conditions: (a) said first contact arm is urged toward, but is prevented by said pad from establishing electrical connection with, said first portion of said first contact element while said second contact arm is spaced apart from said second contact element; (b) said first contact arm only is in electrical connection with said second portion of said first contact element while said second contact arm is spaced apart from said second contact element; and (c) said first contact arm is in electrical connection with said second portion of said rst contact element and said second contact arm is in electrical connection with said second contact element.

2. A progressive switch comprising a case made of insulating material, first and second spaced apart electrically conductive circuit elements in said case, an electrically conductive yoke positioned in said case intermediate said circuit elements, an electrically conductive lever pivotally mounted on said yoke, first and second contact arms on said lever, means for causing said lever to assume any one of three positions relative to said yoke, whereby in position a said first contact arm is urged toward said first circuit element, in position b both said Contact arms are maintained spaced apart from the respective circuit elements, and in position c said second contact arm is urged against said second circuit element, and a contact element electrically connected to said rst circuit element, said contact element being impinged by said first contact arm in both positions b and c only, and means in said case interposed between said first circuit element and said first contact arm preventing electrical connection being made directly therebetween.

3. A progressive switch according to claim 2 wherein said means interposed between said first contact arm and said circuit element comprises a pad of insulating material.

4. A progressive switch according to claim 2 wherein said means interposed between said first contact arm and said circuit element comprises a strip of flexible insulating material, one end of which is connected to said yoke and the other end of which extends freely over said first circuit element.

5. A progressive switch according to claim 2 wherein said means interposed between said first contact arm and said circuit element comprises a cap of insulating material mounted on said first circuit element.

6. A progressive switch according to claim 2 wherein said first circuit element is recessed below the fioor of said case and a portion of said case prevents said first contact arm from making electrical and physical contact with said first circuit element.

7. A progressive switch according to claim 2 wherein said contact element is made of sheet metal connected to said first circuit element and extends in bent form within said case as to be contacted only in positions b and c of said first contact arm.

8. A progressive switch according to claim 7 wherein said contact element comprises at least one contact finger extending above said circuit element, said finger making electrical connection with said first contact arm when the latter is in positions b and c only.

9. A progressive switch according to claim 8 wherein said finger is made of resilient material and is biased in such a manner as to maintain electrical contact with said first contact arrn during positions b and c of said arm.

l0. A progressive switch comprising a case made of insulating material, first and second spaced apart circuit Contact elements in said case, a flexible contact linger electrically connected to said irst Contact element and extending into the interior of said case, an electrically conductive support yoke positioned in said case intermediate said contact elements, a pair of spaced apart pivot shoulders on said yoke, a V-shaped electrically conductive lever mounted pivotably on said shoulders and positionable at will in any one of three positions relative thereto, the apex of said lever being positioned between said shoulders, rst and second contact arms on said lever each extending in opposite directions from the apex of said lever and arrayed at an angle relative to each other, an insulating pad mounted in said case and positioned above said first contact element, an actuating element pivotably mounted in said case and means yieldably biasing said actuating element against said lever, said actuating element being operable upon said lever to cause the latter to move pivotably into any selected one of the t* d following positions where: (a) said first Contact arm is Vurged toward, but is prevented by said pad from establishing electrical connection with, said rst contact element while said second contact arm is spaced apart from said second contact element; (b) said actuating element is positioned upon the interior of the apex of said lever between said shoulders and said rst contact arm makes electrical connection only with said contact finger while said second Contact arrn is spaced apart from said second contact element; and (c) said first contact arm is in electrical connection with said contact finger while said second contact arm is in electrical connection with said second contact element.

References Cited in the le of this patent UNITED STATES PATENTS 1,666,338 Mener Apr. 17, 1928 2,153,396 Sambleson Apr. 4, 1939 2,267,203 Krieger Dec. 23, 1941 2,271,813 Clayton Feb. 3, 1942 2,927,983 Brown Mar. 8, 1960 2,936,347 Larkin May l0, 1960 

2. A PROGRESSIVE SWITCH COMPRISING A CASE MADE OF INSULATING MATERIAL, FIRST AND SECOND SPACED APART ELECTRICALLY CONDUCTIVE CIRCUIT ELEMENTS IN SAID CASE, AN ELECTRICALLY CONDUCTIVE YOKE POSITIONED IN SAID CASE INTERMEDIATE SAID CIRCUIT ELEMENTS, AND ELECTRICALLY CONDUCTIVE LEVER PIVOTALLY MOUNTED ON SAID YOKE FIRST AND SECOND CONTACT ARMS ON SAID LEVER, MEANS FOR CAUSING SAID LEVER TO ASSUME ANY ONE OF THREE POSITIONS RELATIVE TO SAID YOKE, WHEREBY IN POSITION A SAID FIRST CONTACT ARM IS URGED TOWARD SAID FIRST CIRCUIT ELEMENT, IN POSITION B BOTH SAID CONTACT ARMS ARE MAINTAINED SPACED APART FROM THE RESPECTIVE CIRCUIT ELEMENTS, AND IN POSITION C SAID SECOND CONTACT ARM IS URGED AGAINST SAID SECOND CIRCUIT ELEMENT, AND A CONTACT ELEMENT ELECTRICALLY CONNECTED TO SAID FIRST CIRCUIT ELEMENT, SAID CONTACT ELEMENT BEING IMPINGED BY SAID FIRST CONTACT ARM IN BOTH POSITIONS B AND C ONLY, AND MEANS IN SAID CASE INTERPOSED BETWEEN SAID FIRST CIRCUIT ELEMENT AND SAID FIRST CONTACT ARM PREVENTING ELECTRICAL CONNECTION BEING MADE DIRECTLY THEREBETWEEN. 